Raychem Self-Regulating Design Guide

Transcription

Self-regulating cables
This step-by-step design guide provides the tools necessary to design a
self-regulating heat-tracing system for insulated pipes and tubing. For other
applications or for design assistance, contact your Pentair Industrial Heat
Tracing Solutions representative or phone (800) 545‑6258. Also, visit our web site
at www.pentairthermal.com.
Introduction
Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conductive-Polymer Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Self-Regulating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Approvals and Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thermal Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pipe Heat Loss Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Heating Cable Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Determining the Total Length of Heating Cable. . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connection Kit Selection and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pentair invented self-regulating heating cable technology more than 40 years ago
and today has over a billion feet of Raychem brand self-regulating heating cable
installed worldwide.
Self-regulating systems are the preferred choice for most complex pipe-tracing
applications. This is due to their parallel construction, which allows them to be cut to
length and spliced in the field, and their self-regulating output, which provides more
heat where it is needed.
Pentair self-regulating heating cables are certified for use in hazardous locations
and have been tested and approved for unconditional temperature classifications by
worldwide approval agencies.
Conductive-Polymer Technology
Pentair uses innovative conductive-polymer technology in both monolithic (solid
core) and fiber (polymeric fiber wrap) heating cables, as seen in Figures 1 and 2.
The heating element is made of polymers mixed with conductive carbon black. This
special blend of materials creates electrical paths for conducting current between
the parallel bus wires along the entire cable length.
Pentair invented self-regulating
heating cable technology more than
40 years ago and today has over
a billion feet of Raychem brand
self-regulating heating cable
installed worldwide.
INDUSTRIAL HEAT TRACING SOLUTIONS
In each heating cable the number of electrical paths between the bus wires changes
in response to temperature fluctuations. As the ambient temperature surrounding
the heating cable decreases, the conductive core or fiber contracts microscopically.
This contraction decreases electrical resistance and creates numerous electrical
paths between the bus wires. Current flows across these paths to warm the core
or fiber.
EN-RaychemSelfRegulating-DG-H56882
07/16
1 / 32
As the temperature rises, the core or fiber expands microscopically. This expansion
increases electrical resistance, and the number of electrical paths decreases. As a
result,the heating cable automatically begins to reduce its power output.
Modified polyolefin outer jacket (-CR)
or fluoropolymer outer jacket (-CT)
Tinned-copper braid
Modified polyolefin inner jacket or
fluoropolymer inner jacket
Self-regulating conductive core
Nickel-plated copper bus wire
Fig. 1 Monolithic heating cable (BTV, QTVR, HBTV, and HQTV)
Fluoropolymer outer jacket (-CT)
Tinned-copper braid
Fluoropolymer inner jacket
Spacer
Self-regulating polymeric-fiber
heating element
Nickel-plated copper bus wire
Fig. 2 Fiber-wrap heating cable (XTV, KTV and HXTV)
2 / 32
07/16
System Overview
System Overview
Typical Self-Regulating System
A typical self-regulating heating cable system is shown in Figure 3. The heating
cable is cut to length at the job site and attached to the pipe with glass tape. A power
connection kit connects the heating cable bus wires to power in a junction box. Tees
and splices accommodate pipe branches to connect two or three heating cables
together. An end seal kit is used to terminate the end of the heating cable. These
required connection kits are designed and approved to provide a safe and reliable
heat-tracing system. For applications requiring tight temperature control, electrical
system monitoring, or remote operation, consider a control and monitoring system.
Ground-fault
protected power supply
Power connection
Pipe
strap
Heating
cable
Splice or tee
(as required)
Extra cable
at valves
Thermal
insulation
Glass tape
End seal
Heating cable loop for
connection kit installation
Fig. 3 Typical self-regulating heating cable system
Approvals and Certifications
Pentair self-regulating systems are approved and certified for use in nonhazardous and
hazardous locations by many agencies. Please refer to technical data sheets for
more details.
07/16
3 / 32
Thermal Design
Pipe Heat Loss Calculations
Note: All thermal and electrical
design information provided here is
based upon a "standard" installation;
i.e., with heating cable installed on
insulated pipes. For any other method
of installation, consult your Pentair
representative for design assistance.
Note: Heat loss calculation is based
on a nonflowing pipe.
To select the proper heating cable you must first calculate the pipe heat loss, as
outlined in the following four steps:
1Gather the necessary information.
–Tm: Maintain temperature
–Ta: Minimum expected ambient temperature
– Pipe or tubing size and material
– Thermal insulation type and thickness
2Calculate the temperature differential between the pipe maintain temperature
and the minimum ambient temperature.
3Calculate the pipe heat loss.
4Adjust the heat loss to compensate for specific insulation type.
+40
+20
0
−20
−40
Thermal insulation thickness
Pipe or
tubing
diameter
80
60
40
20
°F
Minimum
ambient
temperature
°F
Maintain
temperature
Fig. 4 Pipe heat loss
Thermal Design
1. Gather information
2. Calculate
temperature
differential
3. Calculate heat loss
4. Compensate for
insulation type
Step  Gather the necessary information
To select the heating cable, gather and record the following information:
• Tm: Maintain temperature
• Ta: Minimum expected ambient temperature
• Pipe or tubing size and material
• Thermal insulation type and thickness
Example: Gather information
4 / 32
Maintain temperature
Water freeze protection at 40°F
Minimum ambient temperature
–40°F
Pipe size and material
6-inch diameter, steel
Insulation thickness and type
2-1/2 inch, calcium silicate
07/16
Thermal Design
Thermal Design
Step  Calculate temperature differential ΔT
To calculate the temperature differential (ΔT), use the formula below:
2. Calculate
temperature
differential
Formula
ΔT = Tm – Ta
Example: Calculate temperature differential
4. Compensate for
insulation type
InputTm = 40°F (from Step 1)
InputTa = –40°F (from Step 1)
Calculation
ΔT = 40°F – (–40°F) = 80°F
ΔT = 80°F
Thermal Design
Step  Calculate the pipe heat loss
From Table 1 match the pipe size and insulation thickness with the temperature
differential, ΔT, to find the base heat loss of the pipe (Qb).
2. Calculate
temperature
differential
Example: Calculate pipe heat loss
Input
Pipe size = 6 inch (from Step 1)
4. Compensate for
insulation type
Input
Insulation thickness = 2-1/2 inch (from Step 1)
Input
ΔT = 80°F (from Step 2)
Input
Pipe heat loss = 3.6 W/ft (from Table 1)
From Table 1, Qb must be calculated through interpolation. For this example, 80°F is
3/5 of the difference between the ΔT of 50°F and the ΔT of 100°F:
Qb = 3.6 W/ft + [3/5 x (7.4 – 3.6)] (7.4 is the ΔT of 100°F; 3.6 is the ΔT of 50°F)
CalculationQb = 3.6 + 2.3 = 5.9 W/ft
Pipe heat loss Qb = 5.9 W/ft @ 40°F
Thermal Design
Step  Compensate for insulation type
2. Calculate
temperature
differential
4. Compensate for
insulation type
Multiply the base heat loss of the pipe (Qb) from Step 3 by the insulation
compensation factor (f) from Table 2 to get the total heat loss per foot of pipe (Qt).
FormulaQt = Qb x f
Example: Insulation type compensation
Input
Insulation type = calcium silicate (from Step 1)
Input
f = 1.50 for calcium silicate (from Table 2)
InputQb = 5.9 W/ft (from Step 3)
CalculationQt = 5.9 W/ft x 1.50 = 8.85 W/ft
Qt = 8.85 W/ft at 40°F
Now proceed to the Heating Cable Selection section, page 8, to determine the
heating cable that will compensate for this heat loss.
Note: Heat loss calculations are based on IEEE Standards.
07/16
5 / 32
Table 1 Pipe Heat Loss (W/ft)
Pipe diameter (IPS) in inches
1/4
Insulation
thickness
0.5"
1.0"
1.5"
2.0"
2.5"
3.0"
4.0"
1/2
(ΔT)
3/4
1
1-1/4
1-1/2
2
2-1/2
5.5
11.5
17.9
24.9
3.2
6.8
10.6
14.6
19.1
2.4
5.1
8.0
11.0
14.4
18.1
22.0
2.0
4.2
6.6
9.2
12.0
15.0
18.2
1.8
3.7
5.8
8.0
10.5
13.1
15.9
1.6
3.3
5.2
7.2
9.4
11.8
14.3
1.4
2.9
4.4
6.2
8.1
10.1
12.3
6.5
13.5
21.1
29.2
3.8
7.8
12.2
16.9
22.1
2.8
5.8
9.1
12.6
16.5
20.6
25.1
2.3
4.8
7.5
10.4
13.5
17.0
20.6
2.0
4.2
6.5
9.0
11.7
14.7
17.9
1.8
3.7
5.8
8.0
10.5
13.2
16.0
1.5
3.2
4.9
6.8
8.9
11.2
13.6
Tubing size (inches)
°F
°C
50
100
150
200
50
100
150
200
250
50
100
150
200
250
300
350
50
100
150
200
250
300
350
50
100
150
200
250
300
350
50
100
150
200
250
300
350
50
100
150
200
250
300
350
28
56
84
111
28
56
84
111
139
28
56
84
111
139
167
194
28
56
84
111
139
167
194
28
56
84
111
139
167
194
28
56
84
111
139
167
194
28
56
84
111
139
167
194
3/4
1.9
3.9
6.1
8.5
1.3
2.7
4.2
5.8
7.6
1.1
2.2
3.5
4.8
6.3
7.9
9.6
0.9
2.0
3.1
4.3
5.6
7.0
8.5
0.9
1.8
2.8
3.9
5.1
6.4
7.8
0.8
1.7
2.6
3.6
4.8
6.0
7.3
0.7
1.5
2.4
3.3
4.3
5.4
6.6
2.5
5.2
8.1
11.3
1.6
3.4
5.3
7.4
9.7
1.3
2.8
4.3
5.9
7.8
9.7
11.9
1.1
2.4
3.7
5.2
6.8
8.5
10.3
1.0
2.2
3.4
4.7
6.1
7.7
9.3
1.0
2.0
3.1
4.3
5.7
7.1
8.6
0.9
1.8
2.8
3.9
5.1
6.3
7.7
1
1-1/4
2.9
6.1
9.5
13.2
1.9
3.9
6.1
8.4
11.0
1.5
3.1
4.8
6.7
8.7
11.0
13.3
1.3
2.7
4.2
5.8
7.5
9.4
11.5
1.2
2.4
3.7
5.2
6.8
8.5
10.3
1.1
2.2
3.4
4.8
6.2
7.8
9.5
0.9
2.0
3.0
4.2
5.5
6.9
8.4
3.5
7.2
11.2
15.6
2.2
4.5
7.0
9.7
12.7
1.7
3.5
5.5
7.6
9.9
12.4
15.1
1.4
3.0
4.7
6.5
8.5
10.6
12.9
1.3
2.7
4.2
5.8
7.6
9.5
11.5
1.2
2.4
3.8
5.3
6.9
8.7
10.5
1.0
2.1
3.4
4.6
6.1
7.6
9.3
1-1/2
4.1
8.6
13.4
18.6
2.5
5.2
8.2
11.3
14.8
1.9
4.0
6.3
8.7
11.4
14.3
17.4
1.6
3.4
5.3
7.4
9.6
12.1
14.7
1.4
3.0
4.7
6.5
8.5
10.7
13.0
1.3
2.7
4.3
5.9
7.8
9.7
11.8
1.1
2.4
3.7
5.2
6.7
8.5
10.3
2
4.6
9.6
14.9
20.7
2.8
5.8
9.0
12.4
16.3
2.1
4.4
6.9
9.5
12.4
15.6
19.0
1.8
3.7
5.8
8.0
10.4
13.1
15.9
1.6
3.3
5.1
7.0
9.2
11.5
14.0
1.4
2.9
4.6
6.4
8.3
10.4
12.7
1.2
2.5
4.0
5.5
7.2
9.0
11.0
Note: Pipe heat loss (Qb) is shown in watts per foot. Heat loss calculations are based on IEEE Standards with the following provisions:
•Pipes insulated with glass fiber in accordance with ASTM C547
•Pipes located outdoors in a 20-mph wind
•No insulating air space assumed between pipe and insulation
•No insulating air space assumed between the insulation and outer cladding
•Includes a 10% safety factor
6 / 32
07/16
Thermal Design
Table 1 Pipe Heat Loss (W/ft)
3
7.7
16.0
25.0
34.6
4.4
9.1
14.2
19.7
25.8
3.2
6.7
10.5
14.5
19.0
23.8
28.9
2.6
5.5
8.5
11.8
15.5
19.4
23.6
2.3
4.7
7.4
10.2
13.3
16.7
20.3
2.0
4.2
6.6
9.1
11.9
14.9
18.1
1.7
3.5
5.5
7.6
10.0
12.5
15.2
3-1/2
8.6
18.0
28.1
39.0
4.9
10.2
15.9
22.0
28.7
3.6
7.4
11.6
16.1
21.0
26.3
32.0
2.9
6.0
9.4
13.0
17.0
21.3
25.9
2.5
5.2
8.1
11.2
14.6
18.3
22.2
2.2
4.6
7.1
9.9
12.9
16.2
19.7
1.8
3.8
6.0
8.3
10.8
13.5
16.5
4
9.6
20.0
31.2
43.3
5.4
11.2
17.5
24.2
31.7
3.9
8.1
12.7
17.6
23.0
28.8
35.0
3.1
6.6
10.2
14.2
18.5
23.2
28.3
2.7
5.6
8.7
12.1
15.8
19.8
24.1
2.4
4.9
7.7
10.7
14.0
17.5
21.3
2.0
4.1
6.4
8.9
11.6
14.6
17.7
6
13.6
28.4
44.3
61.5
7.5
15.6
24.3
33.7
44.0
5.3
11.1
17.3
24.0
31.4
39.3
47.8
4.2
8.8
13.8
19.1
24.9
31.2
38.0
3.6
7.4
11.6
16.1
21.0
26.3
32.0
3.1
6.5
10.1
14.0
18.3
23.0
28.0
2.5
5.3
8.3
11.4
15.0
18.8
22.8
8
17.4
36.3
56.6
78.5
9.4
19.7
30.7
42.5
55.6
6.7
13.9
21.6
30.0
39.2
49.2
59.8
5.2
10.9
17.0
23.6
30.9
38.7
47.1
4.4
9.1
14.2
19.7
25.8
32.3
39.3
3.8
7.9
12.4
17.1
22.4
28.1
34.1
3.1
6.4
10.0
13.8
18.1
22.6
27.5
10
12
14
21.4
44.6
69.6
96.6
11.5
24.0
37.4
51.9
67.9
8.1
16.8
26.2
36.3
47.5
59.6
72.4
6.3
13.1
20.5
28.4
37.2
46.6
56.6
5.2
10.9
17.0
23.6
30.9
38.7
47.1
4.5
9.4
14.7
20.4
26.6
33.4
40.6
3.6
7.5
11.8
16.3
21.3
26.7
32.4
25.2
52.5
81.9
113.6
13.5
28.1
43.8
60.7
79.4
9.4
19.6
30.5
42.3
55.3
69.3
84.3
7.3
15.2
23.8
32.9
43.1
54.0
65.6
6.1
12.6
19.7
27.2
35.6
44.6
54.3
5.2
10.8
16.9
23.4
30.6
38.4
46.7
4.1
8.6
13.4
18.6
24.3
30.5
37.1
27.5
57.4
89.5
124.2
14.7
30.6
47.8
66.2
86.6
10.2
21.3
33.2
46.0
60.2
75.4
91.7
7.9
16.5
25.8
35.7
46.7
58.6
71.2
6.6
13.7
21.3
29.5
38.6
48.4
58.8
5.6
11.7
18.3
25.3
33.1
41.5
50.5
4.4
9.3
14.5
20.0
26.2
32.8
39.9
16
31.3
65.2
101.7
141.1
16.6
34.7
54.1
75.0
98.1
11.5
24.0
37.5
52.0
68.0
85.1
103.5
8.9
18.6
29.0
40.2
52.6
65.9
80.2
7.4
15.3
23.9
33.1
43.3
54.3
66.0
6.3
13.1
20.5
28.3
37.1
46.5
56.5
5.0
10.3
16.1
22.3
29.2
36.6
44.5
18
35.0
73.0
113.8
158.0
18.6
38.7
60.4
83.8
109.6
12.9
26.8
41.8
57.9
75.7
94.9
115.4
9.9
20.7
32.3
44.7
58.5
73.3
89.1
8.2
17.0
26.5
36.7
48.0
60.2
73.2
7.0
14.5
22.6
31.4
41.0
51.4
62.5
5.5
11.4
17.8
24.6
32.2
40.3
49.0
20
38.8
80.8
126.0
174.8
20.5
42.8
66.7
92.5
121.0
14.2
29.5
46.1
63.8
83.5
104.6
127.2
10.9
22.8
35.5
49.2
64.3
80.6
98.1
9.0
18.7
29.1
40.3
52.8
66.1
80.4
7.6
15.9
24.8
34.4
45.0
56.3
68.5
6.0
12.4
19.4
26.9
35.2
44.1
53.6
24
46.2
96.3
150.2
208.5
24.4
50.9
79.4
110.0
143.9
16.8
35.0
54.6
75.7
99.0
124.0
150.8
12.9
26.9
42.0
58.2
76.1
95.3
115.9
10.6
22.0
34.3
47.5
62.2
77.9
94.7
9.0
18.7
29.2
40.4
52.8
66.2
80.5
7.0
14.5
22.7
31.4
41.1
51.5
62.6
Table 2 Insulation Factors
Preformed pipe insulation
Glass fiber (ASTM C547)
Calcium silicate (ASTM C533)
Cellular glass (ASTM C552)
Rigid cellular urethane (ASTM C591)
Foamed elastomer (ASTM C534)
Mineral fiber blanket (ASTM C553)
Expanded perlite (ASTM C610)
Insulation factor (f)
1.00
1.50
1.60
0.64
1.16
1.20
1.90
k factor at 50°F (10°C)
(BTU/hr–°F–ft2/in)
0.25
0.37
0.40
0.16
0.29
0.30
0.48
07/16
7 / 32
Heating Cable Selection
Note: The data presented here are
nominal and conservative. Additional
engineering analysis at specific
voltages may allow optimization that
could extend circuit lengths and/
or available power output. Consult
Pentair for more information.
If your application is freeze protection of water piping, follow the five-step heating
cable selection process outlined below.
1Gather the following information:
– Pipe size and material
– Insulation type and thickness
– Maintain temperature (Tm)
– Minimum ambient temperature (Ta )
– Minimum start-up temperature
– Service voltage
– Chemical environment
– Maximum intermittent exposure temperature*
– Electrical area classification**
2Select the heating cable family.
3Select the service voltage.
4Determine the heating cable power output rating.
5Select the jacket type.
* Determines whether a higher exposure temperature heating cable is needed.
** Determines whether special design requirements and connection kits must be used.
If your application is maintenance of another fluid at a temperature other than
40°F (5°C) or is temperature-sensitive, you will need the information above plus
the following data:
Example data
• Process temperature
70°F
• Maximum ambient temperature
105°F
• Fluid degradation temperature***
150°F
***Determines whether thermostatic control is necessary.
heating cable catalog number
Before beginning, take a moment to understand the structure underlying heating cable
catalog numbers. You will refer to this numbering convention throughout the product
selection process. Your goal is to determine the catalog number for the product that
best suits your needs.
XX XXX X–XX
Outer Jacket
CT = Fluoropolymer
CR = Modified polyolefin (BTV only)
Voltage
1 = 120 Volt (100–130 Vac)
2 = 240 Volt (200–277 Vac)
Heating cable family
BTV
HBTV
QTVR
HQTV
XTV
HXTV
KTV
Power output rating (Watts/ft)
Fig. 5 Heating cable catalog number
8 / 32
07/16
To select the heating cable, gather and record the following information:
2. Select heating
cable family
3. Select service
voltage
4. Determine power
output rating
5. Select jacket type
• Pipe size and material
• Insulation type and thickness
• Maintain temperature (Tm)
• Minimum ambient temperature (Ta )
• Minimum start-up temperature
• Service voltage • Chemical environment
• Maximum intermittent exposure temperature • Electrical area classification
Example: Gather necessary information
• Pipe size and material*
6 inches in diameter, steel
• Insulation type and thickness*
2-1/2 inch, calcium silicate
• Maintain temperature (Tm)*
Water freeze protection at 40°F
• Minimum ambient temperature (Ta )*–40°F
• Minimum start-up temperature
0°F
• Service voltage
120 Vac
• Chemical environment
Organic chemicals
• Maximum intermittent exposure temperature**366°F
• Electrical area classification***
Non-hazardous
* From Thermal Design, Step 1
** Determines whether a higher exposure temperature heating cable is needed.
*** Determines whether special design requirements and connection kits must be used.
Step  Select the heating cable family
2. Select heating
cable family
3. Select service
voltage
4. Determine power
output rating
Based on your application’s maintain temperature, pipe material, maximum
exposure temperature, and T-rating, select the appropriate heating cable.
For non-hazardous locations, use Table 3 to select the heating cable family. Base
your selection on your application’s maintain temperature, pipe material, and
maximum intermittent exposure temperature.
For Class I, Division 1 or 2 hazardous locations, also use Table 3 or Table 4, but first
determine the required T-rating for the area.
Temperature identification numbers (T-ratings) are defined by the National Electrical
Code (NFPA 70), Articles 500 and 505; and the Canadian Electrical Code Part I,
Section 18. If the T-rating of the area has been defined, then select a heating cable
from Table 3 or 4 having a T-rating equivalent to or less than the T-rating of this
location (for example, T6 is a lower T-rating than T3).
The purpose of the T-rating is to ensure that electrical equipment does not exceed
the Auto Ignition Temperatures (AIT) of flammables handled in a hazardous location.
If the T-rating for the area has not been defined, use one of the following methods.
07/16
9 / 32
For CSA certification
• Select the material with the lowest AIT in °C.
This temperature is the maximum allowable heating cable sheath temperature.
For FM approval
• Select material with the lowest AIT in °C.
This temperature is the maximum allowable heating cable sheath temperature.
For FM approval, division 1 hazardous locations
• Select material with the lowest AIT in °C.
• Multiply the ignition temperature by 0.8.
This temperature is the maximum allowable heating cable sheath temperature. Use
Table 4 to select the heating cable family.
Table 3 Heating Cable Product Performance Data
Maximum
Maximum
Heating Maximum
continuous intermittent
cable
maintain
exposure
exposure
family temperature temperature*temperature**
T-rating/
maximum
sheath
temperature
BTV
150°F(65°C) 150°F(65°C)
185°F(85°C)
T6185°F(85°C) plastic/
metal
QTVR
225°F(110°C) 225°F(110°C)
225°F(110°C)
T4 275°F (135°C)
KTV
300°F (150°C)
300°F (150°C)
482°F (250°C)2
T2C446°F(230°C) metal only
5XTV1,2 250°F(121°C) 250°F(121°C)
10XTV1,2 250°F(121°C) 250°F(121°C)
15XTV2
250°F(121°C) 250°F(121°C)
482°F (250°C)2
482°F (250°C)2
482°F (250°C)2
T3 392°F(200°C) metal only
15XTV1
20XTV1
20XTV2
482°F (250°C)2
482°F (250°C)2
482°F (250°C)2
T2D419°F(215°C) metal only
250°F(121°C) 250°F(121°C)
250°F(121°C) 250°F(121°C)
250°F(121°C) 250°F(121°C)
Pipe
material
plastic1/
metal only
* With the heating cable power on
** 1000 hours (power on/power off)
1 For plastic pipes please consult TraceCalc Pro design software or contact the
Customer Service Center.
2 The 250°C rating applies to all products printed “MAX INTERMITTENT
EXPOSURE 250C”
Example: Nonhazardous location
Input
Input
Input
40°F maintain temperature (from Thermal Design, Step 1)
366°F intermittent exposure temperature (from Step 1)
Heating cable family XTV (from Table 3)
Catalog number xxXTVx-xx
10 / 32
07/16
Table 4 Heating Cable Product Performance Data
(FM-CID1 Hazardous Locations)
Heating
cable
family
Maximum
Maximum
Maximum
continuous intermittent
maintain
exposure
exposure
temperature temperature* temperature**
T-rating/
maximum
sheath
temperature
HBTV-CT
150°F(65°C)
150°F(65°C)
185°F(85°C)
HQTV-CT
225°F(110°C)
225°F(110°C)
225°F(110°C)
T6 185°F (85°C) plastic/
metal
T4 275°F (135°C) plastic1/
metal only
5HXTV1,2-CT 250°F(121°C)
10HXTV1,2-CT 250°F(121°C)
15HXTV2-CT 250°F(121°C)
250°F(121°C)
250°F(121°C)
250°F(121°C)
482°F (250°C)2
482°F (250°C)2
482°F (250°C)2
T3 392°F (200°C) metal only
15HXTV1-CT 250°F(121°C)
20HXTV1-CT 250°F(121°C)
20HXTV2-CT 250°F(121°C)
250°F(121°C)
250°F(121°C)
250°F(121°C)
482°F (250°C)2
482°F (250°C)2
482°F (250°C)2
T2D419°F (215°C) metal only
T2C446°F (230°C) metal only
T2C446°F (230°C) metal only
Pipe
material
* With the heating cable power on
** 1000 hours (power on/power off)
1 For plastic pipes please consult TraceCalc Pro design software or contact the
Customer Service Center.
2 The 250°C rating applies to all products printed “MAX INTERMITTENT
EXPOSURE 250C”
Example: CID1 hazardous location
For the same inputs, the heating cable family is HXTV from Table 4 on page 11.
For FM Approved systems in CID1 hazardous locations
Due to the potentially hazardous nature of Division 1 locations, the requirements
below must be followed at all times.
• Use only Raychem brand HBTV-CT, HQTV-CT, and HXTV-CT heating cables and
HAK-C-100 connection kits specifically approved by FM.
• Complete and send the field information form found in the Approval for Class I,
Division 1 Hazardous Locations in USA form (H56987), available on
www.pentairthermal.com, to the Pentair Customer Service Center — phone (800)
545-6258, fax (800) 527-5703 — for design verification.
• Be sure the installer completes and returns the Required Installation Record for
Class I, Division 1 Hazardous Locations in USA form (H57426), available on
www.pentairthermal.com, or the one in the back of the installation manual
shipped with the product.
For CSA Certified systems in CID1 hazardous locations
Due to the potentially hazardous nature of Division 1 locations, use only Raychem
brand BTV-CT, QTVR-CT, KTV-CT and XTV-CT heating cables and HAK-C-100
connection kits specifically certified by CSA.
Step  Select the service voltage
2. Select heating
cable family
3. Select service
voltage
4. Determine power
output rating
Service voltage options:
1 = 120 volts (100–130 Vac)
2 = 240 volts (200–277 Vac)
Example: Service voltage selection
Input
XTV heating cable (from Step 2)
Input 120 volts (from Step 1)
Voltage option
1
Catalog number xXTV1-xx
07/16
11 / 32
2. Select heating
cable family
3. Select service
voltage
4. Determine power
output rating
Step  Determine the heating cable power output rating
To select the heating cable power output, use Table 5 to determine the appropriate
power output graph based on the heating cable family and voltage already
determined.
Table 5 Heating Cable Power Output Graph Selection
Pipe material
Heating cable
Voltage
Graph number
Metal pipe
BTV, QTVR, HBTV,
HQTV
120
208
240
277
1
2
3
4
Metal pipe
KTV, XTV and HXTV
120
208
240
277
5
6
7
8
Plastic pipe*
BTV and HBTV
120
208
240
277
9
10
11
12
* Graphs assume the use of aluminum tape over the heating cable.
Using the selected graph, locate the heating cable with thermal output greater than
the heat loss (Qt) at the pipe maintenance temperature (Tm).
If the pipe heat loss, Qt, is between the two heating cable power output curves, select
the higher-rated heating cable. If Qt is greater than the power output of the highestrated heating cable, you can:
• Use two or more heating cables run in parallel.
• Spiral the heating cable.
• Use thicker insulation to reduce heat loss.
• Use insulation material with a lower k factor.
10XTV
QT = 8.9 W/ft
TM = 40°F
Fig. 6 Heating cable thermal output
Spiraling
If spiraling is elected, use the formula below to determine the spiral factor (length of
heating cable per foot of pipe):
Spiral factor = Qt / Heater power output at Tm
When the spiral factor exceeds 6 or the pipe size is less than three inches, consider
using two or more heating cables run in parallel rather than spiraling.
Example: Determine power output rating
12 / 32
Input
XTV heating cable (from Step 3)
Input
Heat loss is 8.7 W/ft (from Thermal Design, Step 4 and Table 1)
Input
10XTV output of 10.2 W/ft exceeds 8.7 W/ft at 40°F (from Graph 5)
Power output rating
Catalog number 10
10XTV1-xx
07/16
Nominal
Output
Watts/foot
22

120 Vac
20
18
 20QTVR1
16

20HQTV1
 15QTVR1
14
 10QTVR1
12
 10BTV1
10
 8BTV1
8
 5BTV1
6
12HQTV1
10HBTV1



8HBTV1
5HBTV1
 3BTV1
4


2
0
70 90 110 130 150 170 190 210 230 250
30 50
(–1) (10) (21) (32) (43) (54) (66) (77) (88) (99) (110) (121)
Pipe Temperature °F (°C)
Graph 1 BTV, HBTV, QTVR, and HQTV nominal power output on metal pipes at 120 volts
Nominal
Output
Watts/foot
22
208 Vac
20
18
 20QTVR2
16

20HQTV2
 15QTVR2
14
 10QTVR2
12
 10BTV2
10
 8BTV2
8
 5BTV2
6
12HQTV2
10HBTV2
8HBTV2
5HBTV2
 3BTV2





4

2
0
30 50
70 90 110 130 150 170 190 210 230 250
(–1) (10) (21) (32) (43) (54) (66) (77) (88) (99) (110) (121)
07/16
13 / 32
Nominal
Output
Watts/foot
22

240 Vac
20
18

 20QTVR2
16
20HQTV2
 15QTVR2
14

 10QTVR2
12
 10BTV2
10
 8BTV2
8
 5BTV2
6

4

12HQTV2
10HBTV2


8HBTV2
5HBTV2
 3BTV2
2
0
30 50
70 90 110 130 150 170 190 210 230 250
(–1) (10) (21) (32) (43) (54) (66) (77) (88) (99) (110) (121)
Nominal
Output
Watts/foot
24
277 Vac

22
20
18

 20QTVR2
20HQTVR2
 15QTVR2
16

14
 10QTVR2
12HQTVR2
12
 10BTV2
10HBTV2 10
 8BTV2
8HBTV2

8
 5BTV2
6
 3BTV2
4
5HBTV2



2
0
30 50
70 90 110 130 150 170 190 210 230 250
(–1) (10) (21) (32) (43) (54) (66) (77) (88) (99) (110) (121)
14 / 32
07/16
Nominal
Output
Watts/foot
25
120 Vac

20
 20XTV1
20HXTV1
 15XTV1
15HXTV1

15
 10XTV1
10HXTV1
 5XTV1
5HXTV1

10

5
0
25 50
75 100 125 150
(–4) (10) (24) (38) (52) (66)
175 200 225 250 275 300
(79) (93) (107) (121) (135) (149)
Graph 5 XTV and HXTV nominal power output on metal pipes at 120 volts
Nominal
Output
Watts/foot
20
18
 20XTV2
20HXTV2
 20KTV-CT
16

208 Vac


14

 15KTV-CT
 15XTV2
12
 10XTV2
10
15HXTV2
10HXTV2
 8KTV-CT

8

 5KTV-CT
 5XTV2
6
5HXTV2
4


2
0
25 50
75 100 125 150
(–4) (10) (24) (38) (52) (66)
175 200 225 250 275 300
(79) (93) (107) (121) (135) (149)
07/16
15 / 32
Nominal
Output
Watts/foot
24
240 Vac
22

20
18
 20XTV2
20HXTV2
16

 15XTV2
15HXTV2 14
 10XTV2
10HXTV2 12
 5XTV2
5HXTV2

10
8
6

4
2
0
25 50
75 100 125 150
(–4) (10) (24) (38) (52) (66)
175 200 225 250 275 300
(79) (93) (107) (121) (135) (149)
Nominal
Output
Watts/foot
24
277 Vac

22
20
18
 20XTV2

20HXTV2 16
 15XTV2
15HXTV2 14
 10XTV2
10HXTV2
 5XTV2
5HXTV2
12

10
8
6

4
2
0
25 50
75 100 125 150
(–4) (10) (24) (38) (52) (66)
175 200 225 250 275 300
(79) (93) (107) (121) (135) (149)
16 / 32
07/16
Nominal
Output
Watts/foot
7
120 Vac

6

 10BTV1
5
10HBTV1
 8BTV1
8HBTV1

4
 5BTV1
5HBTV1
 3BTV1
3

2
1
0
30
(–1)
50
(10)
70
90
110
130
(21)
(32)
(43)
(54)
150
(66)
170
(77)
Graph 9 BTV and HBTV nominal power output on plastic pipes at 120 volts
Nominal
Output
Watts/foot
7
120 Vac

6

 10BTV1
5
10HBTV1
 8BTV1
8HBTV1

4
 5BTV1
5HBTV1
 3BTV1
3

2
1
0
30
(–1)
50
(10)
70
90
110
130
(21)
(32)
(43)
(54)
150
(66)
170
(77)
07/16
17 / 32
Nominal
Output
Watts/foot
8
240 Vac
7
6


 10BTV2
10HBTV2
 8BTV2
5
8HBTV2
 5BTV2
5HBTV2
 3BTV2

4
3

2
1
0
30
(–1)
50
(10)
70
90
110
130
(21)
(32)
(43)
(54)
150
(66)
170
(77)
Nominal
Output
Watts/foot
9
277 Vac
8

7
 10BTV2
10HBTV2 6

 8BTV2
8HBTV2
5

 5BTV2
5HBTV2
 3BTV2
4
3

2
1
0
30
(–1)
50
(10)
70
90
110
130
(21)
(32)
(43)
(54)
150
(66)
170
(77)
18 / 32
07/16
Step  Select the jacket type
2. Select heating
cable family
While QTVR, KTV and XTV heating cables are only available with a CT outer jacket, the
BTV heating cables are also available in a CR version.
3. Select service
voltage
Table 6 Heating Cable Outer Jacket Options
4. Determine power
output rating
Option
Material
Application
CT
Fluoropolymer
Exposure to organic chemicals or corrosives
CR
Modified polyolefin
Exposure to aqueous inorganic chemicals
If you are unsure about the correct jacket for your application, select the CT version
or contact your Pentair representative for assistance.
Example: Jacket type selection
Input
10XTV1-xx heating cable (from Step 4)
Input
Organic chemicals
Jacket type
CT
Catalog number
10XTV1-CT
07/16
19 / 32
Bill of Materials
Now that you have selected the correct heating cable for your application, this
section helps you to determine:
• Total length of heating cable required
• Electrical design, including circuit breaker sizing and selection
• Quantity and type of connection kits and accessories
Determining the Total Length of Heating Cable
To determine the total length of heating cable, follow these six steps:
1Gather the necessary information:
–– Pipe length and diameter
–– Type and number of valves
–– Type and number of pipe supports
–– Start-up temperature
–– Number of circuits and tees in the piping
2Calculate the total length of heating cable for the piping.
3Calculate the total length of heating cable for the valves.
4Calculate the total length of heating cable for the pipe supports.
5Calculate additional heating cable for connection kit installation.
6Add all the lengths together.
Heating
cable
Heating
cable
loop
Extra cable
at valves
Heating cable loop
for connection kit installation
Fig. 7 Typical heating cable layout
Heating Cable Length
2. Calculate cable
length for piping
3. Calculate cable
length for valves
4. Calculate cable
length for supports
5. Calculate cable
length for
connection kits
6. Add all lengths
20 / 32
To determine the total length of heating cable, gather and record the following
information:
• Pipe length and diameter
• Type and number of valves
• Type and number of pipe supports
• Start-up temperature
• Number of circuits and tees in piping
Example: Gather necessary information
Pipe length and diameter
Type and number of valves
Type and number of pipe supports
Start-up temperature
Number of circuits and tees in piping
100 feet of 6-inch pipe
Three 6-inch gate valves
Support shoes, 10 each, 1-foot length
0°F
Power connections: 1
End seals: 3
Pipe tees: 2
07/16
Bill of Materials
Step  Calculate the total length of heating cable for the piping
Example: Total length of cable for piping calculation
2. Calculate cable
length for piping
100 ft of pipe (from Step 1) = 100 ft of cable for single tracing
3. Calculate cable
length for valves
4. Calculate cable
length for supports
5. Calculate cable
length for
connection kits
6. Add all lengths
Step  Calculate the total length of heating cable for the valves
2. Calculate cable
length for piping
3. Calculate cable
length for valves
4. Calculate cable
length for supports
5. Calculate cable
length for
connection kits
6. Add all lengths
Table 7 contains guidelines to determine the amount of additional heating cable
required to compensate for heat loss on valves. For a more detailed analysis, use
TraceCalc Pro design software or consult Pentair.
Multiply the number of valves to arrive at the total additional footage of heating
cable.
Table 7 Recommended Valve Allowance
Pipe diameter
(IPS) (inches)
Heating cable
feet (meters)
1/4
1/2
3/4
1
1-1/4
1-1/2
2
0.3
0.8
1.3
2.0
3.3
4.3
4.3
(0.09)
(0.24)
(0.4)
(0.6)
(1.1)
(1.3)
(1.3)
3
4
6
8
4.3
4.3
5.0
5.0
(1.3)
(1.3)
(1.5)
(1.5)
10
14
18
24
5.6
7.3
9.4
12.6
(1.7)
(2.2)
(2.9)
(3.8)
Comments*
These recommendations are limited by the
amount of heating cable that can physically be
installed on small valves. Heat loss may not be
fully compensated under extreme conditions.
These numbers represent the minimum amount
of heating cable required for a service loop. Additional cable may be required to compensate for
total heat loss.
* Use TraceCalc Pro design software to calculate the exact quantity required for the valve.
Example: Heating cable length for valves calculation
From Table 7 for a 6-inch diameter pipe,
Each valve requires:
5.0 ft
Cable needed for three valves: 3 x 5.0 ft
Total cable length needed for valves:
15.0 ft
07/16
21 / 32
2. Calculate cable
length for piping
3. Calculate cable
length for valves
4. Calculate cable
length for supports
5. Calculate cable
length for
connection kits
6. Add all lengths
Step  Calculate the total length of heating cable for the pipe supports
Support Shoes
For each pipe support shoe, calculate the additional heating cable required as
follows:
Determine the heat loss for one support.
• Formula: Qsupport = 0.7L x (Tm – Ta ), where L = Support length (ft)
(assumes a 0.25-inch steel welded shoe partially shielded from winds)
• Multiply that heat loss by the total number of supports.
• Add 10 percent to the total heat loss for added safety.
• Obtain the heating cable power output per foot from Graph 5.
• Divide the total support heat loss by the heating cable power output per foot to
get the number of feet of heating cable needed.
Example: Total length of cable for pipe supports calculation
Input
10XTV1-CT heating cable (from Cable Selection, Step 5)
Input
10 one-foot welded steel shoe supports (from Step 1)
Heat loss for one support
0.7 x 1 x (40–(–40)) = 56 W
Heat loss for all supports
10 x 56 W = 560 W
Add safety factor
560 W + 10% = 616 W
Heating cable power output
10.2 W/ft (from Step 3 of Cable Selection)
Heating cable required
616 W/10.2 W/ft = 60 ft of heating cable
Step  Calculate additional heating cable for connection kit installation
2. Calculate cable
length for piping
Estimate the number of power connections, tees, and splices for the system. Allow
an additional three feet for each connection kit.
3. Calculate cable
length for valves
Example: Include additional cable
4. Calculate cable
length for supports
Input
1 power connection, 3 end seals, 2 tees
(from Step 1)
5. Calculate cable
length for
connection kits
Total number of connection kits
6 (from Step 1)
Cable needed for 6 connection kits 6 x 3 ft of additional cable
6. Add all lengths
Total cable length for 6 connection kits 18 ft of cable
2. Calculate cable
length for piping
3. Calculate cable
length for valves
4. Calculate cable
length for supports
5. Calculate cable
length for
connection kits
6. Add all lengths
22 / 32
Step  Add all lengths together
Example: Final addition
Cable for piping
100 ft (from Step 1)
Cable for valves
15 ft (from Step 3)
Cable for supports
60 ft (from Step 4)
Cable for connection kits
18 ft (from Step 5)
Sum of all lengths
100 + 15 + 60 + 18 = 193 ft
Total length of heating cable 193 ft
Now that you have the total length of heating cable, you can determine the number
of electrical circuits you will need.
07/16
Bill of Materials
Electrical Design
WARNING: Fire hazard
There is a danger of fire from
sustained electrical arcing if the
heating cable is damaged or
improperly installed. To comply
with Pentair requirements,
certifications, and national
electrical codes, and to protect
against the risk of fire, groundfault equipment protection must be
used on each heating cable circuit.
Arcing may not be stopped by
conventional circuit breakers.
Determining maximum length of heating cable on one circuit breaker
Using Table 8 and Table 9, match the heating cable catalog number at the expected
minimum start-up temperature with the total heating cable length and select a
circuit breaker trip rating. The circuit breaker trip rating should not exceed the
maximum trip rating shown for heating cables of that product family. For example,
the trip rating of a circuit breaker protecting several 10XTV circuits should not
exceed 50 amps. To maximize fault current protection, use the lowest allowable
circuit breaker.
Maximum circuit length per breaker depends on four factors:
1. Heating cable family and catalog number
2. Minimum start-up temperature
3. Service voltage
4. Circuit breaker trip rating
Table 8 Maximum Circuit Length (feet) vs. Circuit Breaker Trip Rating (Amps)
120- and 240-volt heating cables applied to metal pipe with glass tape
120-volt cable
240-volt cable
Heating cable
Start-up
temperature
15 A
20 A
30 A
40 A
50 A
15 A
20 A
30 A
40 A
50 A
3BTV
50°F
330
330
330
330
†
660
660
660
660
†
(10°C)
0°F (–18°C)
200
265
330
330
†
395
530
660
660
†
–20°F
(–29°C)
175
235
330
330
†
350
465
660
660
†
–40°F
(–40°C)
155
205
310
330
†
310
410
620
660
†
5BTV
50°F
(10°C)
230
270
270
270
†
460
540
540
540
†
5HBTV
0°F (–18°C)
140
190
270
270
†
285
380
540
540
†
8BTV
8HBTV
–20°F
(–29°C)
125
165
250
270
†
250
330
500
540
†
–40°F
(–40°C)
110
145
220
270
†
220
295
440
540
†
50°F
(10°C)
150
200
210
210
†
300
400
420
420
†
0°F (–18°C)
100
130
200
210
†
200
265
400
420
†
–20°F
(–29°C)
85
115
175
210
†
175
235
350
420
†
–40°F
(–40°C)
80
105
155
210
†
155
210
315
420
†
10BTV
50°F
(10°C)
120
160
180
180
†
240
315
360
360
†
10HBTV
0°F (–18°C)
80
110
160
180
†
160
215
325
360
†
10QTVR
12HQTV
15QTVR
20QTVR
20HQTV
–20°F
(–29°C)
70
95
140
180
†
145
190
285
360
†
–40°F
(–40°C)
65
85
125
170
†
125
170
255
340
†
50°F
(10°C)
100
130
195
195
†
200
265
390
390
†
0°F (–18°C)
80
105
160
195
†
160
210
320
390
†
–20°F
(–29°C)
70
95
145
195
†
145
195
295
390
†
–40°F
(–40°C)
65
90
135
180
†
135
180
275
365
†
50°F
(10°C)
75
100
150
200
220
160
210
320
340
†
0°F (–18°C)
60
80
120
160
200
125
170
255
340
†
–20°F
(–29°C)
55
70
110
145
185
115
155
235
315
†
–40°F
(–40°C)
50
65
100
135
170
110
145
220
290
†
50°F
(10°C)
60
80
120
160
195
120
160
240
320
390
0°F (–18°C)
45
60
95
125
160
95
125
190
255
320
–20°F
(–29°C)
40
55
85
115
145
85
115
175
235
295
–40°F
(–40°C)
40
55
80
110
135
80
110
165
220
275
5XTV
50°F
(10°C)
180
240
360
385
385
360
480
720
765
765
5HXTV
0°F (–18°C)
160
210
320
385
385
315
420
625
765
765
–20°F
(–29°C)
150
200
305
385
385
295
395
595
765
765
–40°F
(–40°C)
145
195
290
385
385
285
380
570
760
765
07/16
23 / 32
120-volt cable
Heating cable
Start-up
temperature
15 A
20 A
30 A
240-volt cable
40 A
50 A
15 A
20 A
30 A
40 A
50 A
10XTV
50°F
(10°C)
110
145
220
270
270
220
295
440
540
540
10HXTV
0°F (–18°C)
95
130
195
260
270
195
260
385
515
540
15XTV
15HXTV
–20°F
(–29°C)
95
125
190
250
270
185
245
370
495
540
–40°F
(–40°C)
90
120
180
240
270
175
235
355
470
540
50°F
(10°C)
75
100
150
200
220
150
200
300
400
445
0°F (–18°C)
65
90
135
180
220
130
175
265
355
440
–20°F
(–29°C)
65
85
130
170
215
125
165
250
335
420
–40°F
(–40°C)
60
80
125
165
205
120
160
240
320
405
20XTV
50°F
(10°C)
60
80
120
160
190
115
150
230
305
380
20HXTV
0°F (–18°C)
50
70
105
140
180
100
135
205
275
345
5KTV
8KTV
15KTV
20KTV
–20°F
(–29°C)
50
65
100
135
170
100
130
200
265
330
–40°F
(–40°C)
50
65
100
130
165
95
125
190
255
320
50°F
(10°C)
180
240
360
385
385
360
480
720
765
765
0°F (-18°C)
160
215
320
385
385
320
430
640
765
765
–20°F
(-29°C)
155
205
305
385
385
310
415
620
765
765
–40°F
(–40°C)
145
195
290
385
385
300
400
600
765
765
50°F
(10°C)
130
170
260
300
300
260
345
515
600
600
0°F
(-18°C)
115
150
225
300
300
230
310
465
600
600
–20°F
(-29°C)
110
145
215
290
300
225
295
445
595
600
–40°F
(–40°C)
105
140
205
275
300
215
285
430
570
600
50°F
(10°C)
80
105
160
215
220
160
215
320
425
440
0°F
(-18°C)
75
95
145
195
220
145
190
285
385
440
–20°F
(-29°C)
70
95
140
185
220
140
185
275
370
440
–40°F
(–40°C)
65
90
135
180
220
135
180
265
355
440
50°F
(10°C)
55
75
115
155
185
115
155
230
305
375
0°F
(-18°C)
50
70
105
140
175
105
140
210
280
350
–20°F
(-29°C)
50
65
100
135
165
100
135
200
270
335
–40°F
(–40°C)
50
65
95
130
160
95
130
195
260
325
† Not permitted
For a fully optimized design, use TraceCalc Pro design software or contact your Pentair representative.
Note: Pentair and the U.S. National Electrical Code require both ground-fault protection of equipment and
agrounded metallic covering (usually braid) on all heating cables. All Raychem products meet the metallic covering requirement.
Following are some of the ground-fault breakers that satisfy this equipment protection requirement: Square D Type QOB-EPD or
QO-EPD; Raychem/Square D Type GFPD EHB-EPD (277 Vac); Cutler Hammer (Westinghouse) Type QBGFEP.
208-volt cable
Heating cable
3BTV
5BTV
5HBTV
24 / 32
277-volt cable
Start-up
temperature
15 A
20 A
30 A
40 A
50 A
15 A
20 A
30 A
40 A
50 A
50°F (10°C)
635
635
635
635
†
710
710
710
710
†
0°F(–18°C)
380
510
635
635
†
425
570
710
710
†
–20°F (–29°C)
335
445
635
635
†
360
500
710
710
†
–40°F (–40°C)
300
395
595
635
†
335
440
670
710
†
50°F (10°C)
430
505
505
505
†
500
590
590
590
†
0°F(–18°C)
270
355
505
505
†
310
415
590
590
†
–20°F (–29°C)
235
310
470
505
†
270
360
545
590
†
–40°F (–40°C)
210
275
415
505
†
240
320
480
590
†
07/16
Bill of Materials
208-volt cable
Heating cable
8BTV
8HBTV
10BTV
10HBTV
10QTVR
12HQTV
15QTVR
20QTVR
20HQTV
5XTV
5HXTV
10XTV
10HXTV
15XTV
15HXTV
Start-up
temperature
50°F (10°C)
277-volt cable
15 A
20 A
30 A
40 A
275
370
385
385
50 A
†
15 A
20 A
30 A
40 A
330
445
465
465
50 A
†
0°F(–18°C)
185
245
370
385
†
220
295
445
465
†
–20°F (–29°C)
160
215
320
385
†
195
260
390
465
†
–40°F (–40°C)
145
190
290
385
†
170
230
350
465
†
50°F (10°C)
220
290
330
330
†
265
350
400
400
†
0°F(–18°C)
145
200
300
330
†
180
240
360
400
†
–20°F (–29°C)
130
175
260
330
†
160
210
315
400
†
–40°F (–40°C)
115
155
235
310
†
140
190
280
375
†
50°F (10°C)
190
250
365
365
†
210
280
415
415
†
0°F(–18°C)
150
195
300
365
†
170
225
340
415
†
–20°F (–29°C)
135
180
275
365
†
155
205
315
415
†
–40°F (–40°C)
125
170
260
345
†
140
190
290
385
†
50°F (10°C)
145
190
290
310
†
175
230
350
375
†
0°F(–18°C)
115
155
230
310
†
140
185
280
375
†
–20°F (–29°C)
105
140
215
285
†
125
170
260
345
†
†
–40°F (–40°C)
100
130
200
265
†
120
160
240
320
50°F (10°C)
110
145
220
290
355
135
180
265
355
430
0°F(–18°C)
85
115
175
230
290
105
140
210
280
355
–20°F (–29°C)
80
105
160
215
270
95
130
195
260
325
–40°F (–40°C)
75
100
150
200
250
90
120
180
245
305
50°F (10°C)
355
475
715
755
755
390
520
780
825
825
0°F(–18°C)
310
415
620
755
755
340
455
675
825
825
–20°F (–29°C)
290
390
590
755
755
320
425
645
825
825
–40°F (–40°C)
280
375
565
750
755
310
410
615
820
825
50°F (10°C)
215
290
435
535
535
235
315
465
570
570
0°F(–18°C)
190
255
380
510
535
205
275
410
545
570
–20°F (–29°C)
180
240
365
490
535
195
260
390
525
570
–40°F (–40°C)
170
230
350
465
535
185
250
375
500
570
50°F (10°C)
145
195
295
390
435
160
210
320
425
470
0°F(–18°C)
125
170
260
345
430
140
185
280
375
465
–20°F (–29°C)
120
160
245
325
410
135
175
265
355
445
–40°F (–40°C)
120
155
235
315
400
125
170
255
340
430
20XTV
50°F (10°C)
115
150
230
305
380
125
160
250
330
410
20HXTV
0°F(–18°C)
100
135
205
275
345
110
145
220
300
375
–20°F (–29°C)
100
130
200
265
330
110
140
215
285
355
5KTV
8KTV
–40°F (–40°C)
95
125
190
255
320
105
135
205
275
345
50°F (10°C)
340
450
680
720
720
380
510
765
810
810
0°F(–18°C)
300
405
600
720
720
340
455
680
810
810
–20°F (–29°C)
290
390
585
720
720
330
440
660
810
810
–40°F (–40°C)
280
375
565
720
720
320
425
635
810
810
50°F (10°C)
245
325
485
565
565
275
365
545
635
635
0°F(–18°C)
215
290
440
565
565
245
330
495
635
635
–20°F (–29°C)
210
280
420
560
565
240
315
470
630
635
–40°F (–40°C)
200
270
405
535
565
230
300
455
600
635
07/16
25 / 32
208-volt cable
Heating cable
15KTV
20KTV
Start-up
temperature
50°F (10°C)
277-volt cable
15 A
20 A
30 A
40 A
50 A
15 A
20 A
30 A
40 A
50 A
150
200
300
400
415
170
230
340
450
465
0°F(–18°C)
135
180
270
360
415
155
200
300
410
465
–20°F (–29°C)
130
175
260
350
415
150
195
290
390
465
–40°F (–40°C)
125
170
250
335
415
145
190
280
375
465
50°F (10°C)
110
145
215
285
355
120
165
245
325
400
0°F(–18°C)
100
130
200
265
330
110
150
225
300
370
–20°F (–29°C)
95
125
190
255
315
105
145
210
285
355
–40°F (–40°C)
90
120
185
245
305
100
140
205
275
345
† Not permitted
Note: Pentair and the U.S.
National Electrical Code require both
ground-fault protection of equipment
and agrounded metallic covering
(usually braid) on all heating cables.
All Raychem products meet the
metallic covering requirement.
Following are some of the ground-fault
breakers that satisfy this equipment
protection requirement: Square D Type
QOB-EPD or QO-EPD; Raychem/
Square D Type GFPD EHB-EPD (277
Vac); Cutler Hammer (Westinghouse)
Type QBGFEP.
Example: Determine maximum length of heating cable on one circuit breaker
Input
10XTV1 heating cable (from Cable Selection, Step 3)
Input
120 volts (from Cable Selection Step 1)
Input
0°F start-up temperature (from Cable Selection, Step 1)
Input
Maximum circuit length = 195 feet on a 30-amp breaker (from Table 8)
If the total length of cable exceeds 195 feet, you must use a 40-amp circuit breaker,
which allows up to 260 feet.
Determine minimum number of circuits
Example: Minimum number of circuits calculation
Input 195 ft allowed per 30-amp circuit (from Table 8)
Input Number of circuits Total circuit length = 193 ft (from Bill of Materials, Step 6)
1 circuit
If the total length of heating cable required exceeded 195 ft, you would need to split
the total length into two separate circuits or use a larger circuit breaker size.
Power
Line 1
Line 3
Line 2
Line 1 + Line 2 + Line 3 ≤ Maximum circuit length
Fig. 8 Maximum heating cable circuit length
Ground-fault protection
To minimize the danger of fire from sustained electrical arcing if the heating
cable is damaged or improperly installed, and to comply with the requirements of
Pentair, agency certifications, and national electrical codes, ground-fault equipment
protection must be used on each heating cable branch circuit. Arcing may not be
stopped by conventional circuit protection. Many Raychem control and monitoring
systems meet the ground-fault protection requirement.
26 / 32
07/16
Bill of Materials
Connection Kit Selection and Accessories
WARNING: Fire hazard
To prevent fire or shock, Raychem
brand specified connection kits
must be used. Do not substitute
parts or use vinyl electrical tape.
Overview
Pentair offers a full range of connection kits for power connections, splices, and
end seals on self-regulating cable systems. These connection kits must be used to
ensure proper functioning of the product and compliance with warranty, code, and
approvals requirements.
Different power connection, end seal, splice, and tee kits are required depending
on the area classification. Data sheets can be found on the Pentair web site,
www.pentairthermal.com, or the Technical data sheet section of the Industrial
Heat Tracing Solutions Products & Services Catalogue (H56550).
Non-Hazardous and hazardous location connection kits
Figure 9 shows the connection kits and accessories available for self-regulating
heating systems.


JBS-100-ECP-A
Non-hazardous locations only

E-150
PMKG-LT
E-100-L
JBM-100-A

T-100
S-150
E-100
T-100
JS-100-A


JBS-100-L-A
Fig. 9 Self-regulating heating system connection kits and accessories
07/16
27 / 32
Table 10 Nonhazardous and Hazardous Connection Kits and Accessory Selection
Description
Catalog number
Quantity
Connection Kits
1 per circuit
 Power connection
Single heating cable
Single heating cable with light
Single heating cable with digital electronic controller
JBS-100-A
JBS-100-L-A
JBS-100-ECP-A (nonhazardous locations only)
Single heating cable (user-supplied junction box)
Multiple heating cables (1, 2, or 3)
Multiple heating cable with light
JS-100-A
JBM-100-A
JBM-100-L-A
1 per splice
 Splice connection
Above insulation
Below insulation
T-100
S-150
1 per tee
 Tee connection
Above insulation
Below insulation
T-100
PMKG-LT (BTV and QTVR only)
1 per power connection plus 1 per tee
 End seal
Above insulation
Above insulation with light
Below insulation
E-100
E-100-L-A
E-150
Accessories
Attachment tape, labels, and pipe straps
Controls (optional)
 Thermostat — Control and Monitoring design guide (H56889)
Cid1 hazardous location Connection Kits
All power connections, splices, tees, and end seals in a Division 1 location must
use the HAK-C-100 connection kit and an HAK-JB3-100 or a Division 1 Nationally
Recognized Testing Lab (NRTL) approved junction box.
HAK-JB3-100
junction box
HAK-C-100
connection kit
Note: Connection kit, junction box,
mounting bracket, and pipe strap
sold separately
Fig. 10 CID1 hazardous location connection kits
Table 11 CID1 Connection Kit Selection
Additional
materials required
Connection
type
Power
Splice
Tee
End seal
Number of
HAK-C-100
kits
required
Number
of holes
required on
the junction
box
1
2
3
1
2
2
3
1
Junction box
catalog
number
HAK-JB3-100
HAK-JB3-100
HAK-JB3-100
HAK-JB3-100
Mounting
brackets*
1
1
1
1
Pipe
straps
1
1
1
1
* Catalog number UMB
28 / 32
07/16
Bill of Materials
The HAK-C-100 kit is FM approved and CSA certified to be used for all power
connections, splices, tees, and end seals in Division 1 locations.
System Connection Kits
JBS-100-A Power connection for one heating cable in nonhazardous and hazardous
locations. Includes cold-applied heating cable core seal. Requires one pipe strap to
be ordered separately.
¨
JBS-100-A
JBS-100-ECP-A
JS-100-A
¨
JBM-100-A
With LED indicator light, order JBS-100-L-A
JBS-100-ECP-A Power connection and digital electronic controller. Requires one
pipe strap to be ordered separately. Non-hazardous locations only.
JS-100-A Junction box stand for one heating cable in nonhazardous and hazardous
locations. A separate customer-supplied NEMA 4X junction box is required. Includes
cold-applied heating cable core seal. Requires one pipe strap to be ordered
separately.
JBM-100-A Multiple-entry power connection for up to three heating cables. Can
also be used as a splice or tee connection. For use in nonhazardous and hazardous
locations. Includes cold-applied heating cable core seal. Requires two pipe straps to
be ordered separately.
With LED indicator light, order JBM-100-L-A.
C75-100-A
T-100
S-150
C75-100-A A NEMA 4X-rated gland kit (3/4" NPT) used to transition heating cables
into a junction box in nonhazardous and hazardous locations. Includes cold-applied
heating cable core seal. A terminal block (3 x 12 AWG) is included. This kit does not
include the junction box or the conduit.
T-100 Tee or splice connection for up to three heating cables in nonhazardous and
hazardous locations. Includes cold-applied heating cable core seal. Requires two
pipe straps to be ordered separately.
S-150 Splice kit for heating cables in nonhazardous and hazardous locations.
Includes cold-applied heating cable core seal.
E-100-A End seal for heating cable in non-hazardous and hazardous locations.
Reenterable. Includes cold-applied heating cable core seal. Requires one pipe
strap to be ordered separately.
E-100-A
With LED indicator light, order E-100-L-A
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E-150
HAK-JB3-100
junction box
E-150 Low-profile end seal for heating cable in non-hazardous and hazardous
locations. Includes cold-applied heating cable core seal.
HAK-C-100 CID1 hazardous location connection kit for one heating cable. Junction
box ordered separately.
HAK-JB3-100 CID1 hazardous location junction box for up to three entries. Requires
one pipe strap and a universal mounting bracket (UMB) to be ordered separately.
HAK-C-100
connection kit
Accessories
GT-66 Glass Installation Tape
• For use on pipes other than stainless steel
• 1/2" x 66' roll
• Strap at 1-foot intervals at minimum application temperature of 40°F (5°C)
GT-66
GS-54
AT-180
GS-54 Glass Installation Tape
• For use on all pipes, particularly stainless steel
• 1/2" x 54' roll
• Strap at 1-foot intervals at minimum application temperature of –40°F (–40°C)
AT-180 Aluminum Tape
• For use on all pipe materials
• 2-1/2" x 180' roll
• Temperature class: 300°F (150°C)
• Minimum installation temperature: 32°F (0°C)
Glass tape
across heating cable
Aluminum tape
over heating cable
t
1 foo
Fig. 11 Tape installation
Table 12 Attachment Tape Requirements
Rolls needed per 100 ft of cable
Tape type
GT-66
GS-54
AT-180
30 / 32
1/2
1
2
3
4
6
8
0.6
1.2
4
4
6
8
10
0.6
1.2
4
6
6
10
12
Use one foot of tape per foot of heating cable
07/16
Bill of Materials
ETL (Electric Traced Label)
ETL
Attach the label to the outside of the thermal insulation weather barrier to indicate
presence of electrical heat tracing. Use one label for every 10 feet (3 m) of pipe,
alternating on either side of the pipe.
Pipe Straps
Pipe strap
Stainless steel pipe straps to attach connection kit to the heat-traced pipe. Use
Table 13 below to assist with pipe strap selection.
Table 13 Pipe Strap Selection
Catalog number
Pipe size
PS-01
For conduit ≤ 1"
PS-03
For connection kits on pipes with dimensions < 2"
PS-10
For connection kits on pipes with dimensions 2" – 10"
PS-20
For connection kits on pipes with dimensions 10" – 19.5"
Small Pipe Adapters
JBS-SPA
JBS-SPA Adapter for mounting E-100, JBS-100, and JS-100-A to small pipe.
(≤ 1" diameter)
JBM-SPA
JBM-SPA Adapter for mounting JBM-100 and T-100 to small pipe. (≤ 1" diameter)
Conduit Drain
JB-DRAIN-PLUG-3/4IN
JB-DRAIN-PLUG-3/4IN Conduit drain for JBS-100, JBM-100, and JS-100-A.
Controls
For a complete selection of control and monitoring products, including thermostats,
see Control and Monitoring design guide (H56889)
Raychem 920
Raychem 910
NGC-30 system
NGC- system
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Pentair, TraceCalc Pro, BTV, QTVR, HBTV, HQTV, XTV, KTV, HXTV, HAK-C-100, JBS-100-ECP-A, JBM-100-A, JS-100-A, JBS-100-L-A, JBS-100-A, S-150,
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property of their respective owners. Pentair reserves the right to change specifications without prior notice.
© 2001-2016 Pentair.
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Raychem Self-Regulating Design Guide

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